Feed Mill Automation

FEEDMILL AUTOMATION

Sterling Systems & Controls, Inc. offers complete customized feedmill process control and feed mill automation systems solutions.  Feed is produced for nearly every domesticated animal, including petfood for our dogs and cats. Feed production is done in a feed mill.  The term “feed mill” and the word “feedmill” are used interchangeably. Sterling Systems can provide feed mill automation systems. Also, it offers automation and control for individual aspects of the feedmill manufacturing process. In addition, Sterling Systems can provide fully integrated feed mill automation turn key systems.

The Sterling Systems automated batching systems are at the heart of feed mill automation solutions. WebCentral software is the central nervous system. It allows for the management of Ingredients, Formulas, Bin Assignments, Schedules and other data tables. In addition, you can view and print historical batching and process data reports. PLC based control systems are constrained by limited PLC memory. They hold a limited amount of data (Ingredients, Formulas, etc) at one time. WebCentral stores data in a Microsoft SQL Server (or SQL Express) database. Nearly unlimited amount of data can be stored. WebCentral monitors key process and batching data and alarm conditions in the feed mill automation system. It provides logging and historical analysis of this data. PLC’s and Control Systems are good at controlling equipment. Computers and Databases are good at managing data. WebCentral provides the means to bridge these two worlds. This provides a seamlessly integrated turn key feed mill automation solution.

Feed Mill Automation:

  • Controls Design
  • Receiving
  • Grinding (Hammer Mill & Roller Mill)
  • Automated Batching
  • Pelleting
  • Finish Feed Routing
  • Loadout Systems (Fixed Truck Scales & Lorry Scales)
  • Automated Bulk Material Handling Systems
  • Bulk Bag Unloading Systems
  • Major, Minor & Micro Ingredient Systems
  • Liquid Weighing or Metering Systems (Optimized for fat and molasses as well as many other liquids commonly used in the Animal Feed Mill facilities)
  • Intergation With Business ERP, through WebCentral

Key Features:

  • Feed mill automation systems integrate into business systems with either proprietary or non-proprietary software
  • Incorporates standard or custom features required by each feedmill process control application
  • Accommodates WonderWare, Intellution and other industrial software packages
  • Scheduling
  • Formulation Management & Storage
  • Raw Material Management, Inventory and Usage
  • Material Parameters (Tolerance, Feeder Speed, Jog, and Pre-act/Cutoff…)
  • Raw Material Lot Tracking (Bar Code, RFID)
  • Process Validation (Bar Code, RFID…)
  • Equipment Parameters (Scales, Mixer, Dry Ingredient Feeders, Liquid Meters…)
  • Finished Batch Tracking
  • Abnormal Condition Alarms and Tracking
  • Remote Batching & Data Access Software (WebCentral)
  • Troubleshooting & Diagnostics Features (Local & Remote)
  • Least Cost Formulation Software Interfaces

Receiving SystemRECEIVING FEED MILL

  • Receiving System Automation Screen
  • Raw Ingredient Tracking
  • Scale Integration
  • Source Selection
  • Destination Selection
  • Auto Routing with Interlocks
  • Equipment Monitoring for Abnormal Conditions

Grinding System

  • Grinding System Automation Screen
  • Pre-Ground Product Storage Routing To Grinding BinsBLENDING MIXING
  • Grinding Bins Level Control
  • Feeder Speed Varied Automatically based upon Mill Load
  • Grinding Equipment Monitoring for Maximum Throughput
  • Equipment Monitoring for Abnormal Condition & Run times
  • Auto Routing of Ground Product

Batching System

 

Pelleting System

 

  • Pellet Mill Automation Screen
  • Amps
  • No Roll Slip
  • Pellet Mill Inlet Mash Temperature
  • Steam Modulating Valve
  • Lineator Roll Gap Software and I/O
  • Equipment Monitoring for Abnormal Conditions & Run times
  • Pellet Mill Setup Screens (password protected)
  • Parameter Storage for Operating Formula and Pellet Mill:
    • Operating instructions
    • Run set-points
    • Amps
    • Temperatures
    • Speeds for the pellet mill.
  • Unique parameters Stored for Multiple Formulas
  • Liquids can be controlled by the PELLET MILL workstation.
  • Liquids Added Either at the Conditioner or Die
  • Auto/Man – Operate in Manually and Switch to Auto “on the fly”

Loadout Systems

  • Truck Loadout Automation ScreenLOADOUT
  • Scale Integration
  • Shuttle Conveyors or Trolley Systems
  • Multiple Compartment Filling
  • Truck Tracking
  • Customer Tracking
  • Finished Product Tracking